Wood embossing apparatus



July 16. 1968 A. CRAMER WOOD EMBOSSING APPARATUS 3 SheetsSheet 1 Filed March 8, 1966 INVENTOR.

8 E. mm mm LLOYD A. GRAMER July 16, 1968 CRAMER 3,393,294

WOOD EMBOSSING APPARATUS Filed March 8, 1966 5 Sheets-Sheet 2 HIGH RESISTANCE METAL FIG. l2

INVENTOR. LLOYD A. CRAMER July 16, 1968 L. A. CRAMER 3,393,294

WOOD EMBOSSING APPARATUS Filed March 8, 1966 5 Sheets-Sheet 3 r v FIG.||

INVENTOR. LLOYD A. ORAMER BY I FIG.|O

United States Patent 3,393,294 WOOD EMBOSSING APPARATUS Lloyd A. Cramer, 5701 Brookwood Drive, Greensboro, N.C. 27407 Filed Mar. 8, 1966, Ser. No. 532,783 Claims. (Cl. 219388) ABSTRACT OF THE DESCLOSURE Apparatus for embossing or embellishing wood panels or faces of veneer to produce a distressed or simulated wormy effect or appearance in the panels or veneer faces having searing means to burn a random design into the surfaces of advancing materials.

Background, brief summary and objectives of the invention Rather recent developments in the woodworking industry have made possible the economical production of plywood panels to simulate solid dressed lumber boards. This enables the builder to furnish interior wall surfaces at much less cost than would be possible should these surfaces be made of solid lumber.

Methods and machinery for producing stock panel plywood are well known in the art and the preferred process is to bond layers of veneers faced with wood such as walnut, pecan, cherry or oak in a hot plate press. The plywood sheet after having been trimmed and sanded is passed through grooving machines which trench the veneer surface thus dividing the panel into sections which appear to be dressed lumber planks placed in a side-byside relationship.

The plywood industry has used natural defects in face veneers to provide rustic or distressed appearances of interior walls, but the open knotholes all must be filled by hand thus keeping the cost involved in natural distressing very high.

Methods of producing simulated antique furniture are known in the furniture industry and include various techniques such as drilling holes in the wooden surfaces or pounding on the surface with a variety of unusually shaped instruments so as to achieve a worn or antique effect prior to finishing the furniture piece. An obvious drawback of this particular method is the high cost of labor necessary to hand tool and prepare each furniture item prior to finishing.

To complement the paneling heretofore known to those in this area of technology and to provide materials for the construction of antique furniture, I have devised a fully automatic machine to simulate the distressed appearance of plywood, veneer or other wood products. My apparatus is designed particularly to imitate the appearance of natural wormy chestnut which has become extremely desirable for wall paneling and furniture construction but is not available in volume.

My apparatus in its preferred form is cooperatively positioned proximate a movable feed table so that advancing plywood panels can be positively engaged for patterning, embossing and etching, in a rapid and eflicient manner. The embossing mechanism in a preferred form is comprised of a pressure roller assembly having two spacedapart pressure rollers with a continuous track or web spanning the rollers and moving upon their rotation. The track itself releasably carries a plurality .of segments in a side-by-side relationship about its periphery. Additionally, these segments, in turn, contain a plurality of randomly spaced embossing or woodburning tools that are held in a panel-engaging position by threadable means for expeditious replacement in the event one or more become damaged during the embossing operation. In order to insure that no two finished or embossed plywood panels bear the same random pattern or design of simulated worm holes and grooves, it has been found preferable to use a plurality of embossing assemblies in a side-by-side relationship with each of the assemblies having the two pressure rollers spaced apart at different intervals so that no two webs move in unison.

In order to elevate the temperature of the embossing tool sufficiently to burn, score or sear the plywood panels as they are moved beneath the pressure roller assembly, a variety of heating means are available, those particularly recommended for this application being a bank of infra-red lamps strategically placed to heat the embossing tools just prior to their contact with the advancing plywood panels, and an alternate electrically operated system whereby circuits are formed with the embossing tools becoming series components thereof for a preselected time interval just prior to the embossing tools contact with the advancing panels.

Since the present invention in its preferred form contemplates an arrangement somewhat analogous to a tractor tread, each embossing tool, once it has come in contact with the plywood panel, will remain in contact with that panel for a predetermined period of time until the second pressure roller of the assembly lifts the tool from the panel and rotates it therearound through a return path.

It can be seen that the unique configuration of the pressure roller assemblies allows any patterning effect to be accomplished without the necessity of repeating that effect so as to destroy the natural wormy appearance of the wood. Additionally, the number of pressure assemblies can be increased at will to accommodate any number of plywood panels in a side-by-side relationship as they move through the total apparatus. Production can be multiplied by whatever factor is desired with such an arrangement.

With the following general description of a preferred embodiment of the present invention in mind, it is, therefore, an object to provide an apparatus for embossing plywood panels, lumber, veneer or other wood products with natural simulated wormy chestnut patterns.

Another object of this invention is to provide a novel pressure assembly for embossing plywood panels, veneer, lumber or other wood products that will insure that the simulated, wormy patterning effect will not be repeated.

A further object of the present invention is to provide a novel embossing apparatus for embellishing plywood panels and the like that can be automatically operated and run at high speeds to increase productivity.

Yet another object of this invention is to provide a novel heating arrangement so that the embossing tools for embellishing the finished surfaces of plywood panels and the like can be heated sufficiently to burn simulated wormholes into these surfaces.

Still another object of this invention is to provide a method of embossing plywood panels rapidly and economically so that it lends itself to quantity production in a continuous flow operation by means of apparatus of a relatively simple and inexpensive nature.

Yet still another object of my invention is to provide a suitable apparatus for embossing plywood panels whereby the method of the present invention can be carried out rapidly, efficiently and economically.

A further object of this invention is to provide alternate heating and embossing means to suit any number of particular situations, particularly those where the use of one particular embodiment would not be physically or economically feasible.

The invention possesses other objects, features and advantages, some of which, with the foregoing, will be Figure description FIG. 1 is a side elevational view of the preferred embodiment of the present invention illustrating the embossing mechanism including the pressure roller assembly positioned proximate a panel advancing conveyor with the track carried embossing tools positioned to contact advancing plywood panels for subsequent embossing.

FIG. 2 is a top plan view of the embossing apparatus and conveyor assembly shown in FIG. I particularly illustrating the advancement of plywood panels from a plain finished surface stage through the embossing mechanism and finally to the end of the process where the simulated wormy chestnut panels emerge.

FIG. 3 is a plan sectional view of a number of pressure roller assemblies showing the support structure and drive mechanisms for rotating the rollers and driving the tracks carried thereby.

FIG. 4 is an enlarged perspective fragmented view of a portion of the continuous track or web that is carried by the pressure rollers and which in turn supports a plurality of segments that hold the randomly spaced embossing tools.

FIG. 5 is an enlarged single segment which is supported by the continuous track or web illustrated in FIG. 4 supporting a number of threadably received and maintained embossing tools.

FIG. 6 is an enlarged side elevational and sectional view of differently fashioned embossing tips or searing needles which are carried by the individual segments such as shown in FIG. 5.

FIG. 7 is a fragmentary plan view of a portion of a finished and embossed plywood panel which resembles natural wormy chestnut oak that has been passed through the apparatus constituting the present invention.

FIG. 8 is an alternative embodiment of the present inventive concept disclosing the use of a plurality of different diametered pressure rollers which in turn bear randomly positioned embossing tools to form simulated wormy patterns in plywood panels and lumber passed thereagainst.

FIG. 9 is another alternative embodiment of the present inventive concept utilizing equal and opposed pressure roller assemblies for embossing and embellishing advancing plywood panels or lumber to simulate wormy chestnut oak.

FIG. 10 is yet another alternative embodiment of the present inventive concept showing an end elevational view of an inclined conveyor apparatus in conjunction with a metal particle distributing mechanism for sprinkling an advancing plywood panel with hot metal particles to produce a simulated wormy effect in the panel or lumber surface.

FIG. 11 is a greatly enlarged side elevational sectional view of a proposed embossing tool to be used with any of the embodiments of the present inventive concept disclosed therein which utilizes a biasing swivel assembly to permit extended contact of the embossing unit against the plywood surface until that surface is sufficiently scored or seared to produce a simulated worm effect.

FIG. 12 is a representative circuit diagram which may be used to elevate the temperature of the embossing tips to sear the panels or veneer faces upon contact therewith.

Detailed description of the disclosure Referring now to the drawings and particularly to FIG. 1, there is illustrated a plywood panel embossing apparatus generally designated 10 which includes an advancing conveyor belt 12 extending for any preselected length preferably to a conventional stacking or sorting apparatus which could individually or sequentially discharge a single plywood panel 13 onto the belt 12 for movement toward (see arrow) a pressure roller assembly generally designated 14-. The conveyor belt 12 is assembled in a conventional 'manner and preferably has a plurality of supporting legs or struts 16 to maintain the belt 12 movably positioned a suitable distance from the floor 18 along with a plurality of rotating supporting pulleys 20 positioned to sustain belt 12 in a condition that is substantially horizontal to floor 18 and without appreciable sag. Pulleys 20 are driven by conventional means such as an electrical motor 24 having an external drive pulley 26 and belt 2% which positively engages the drive wheel 30 of one or more of pulleys 20. Motor 24 has a variable gear box arrangement 32 to enable the speed of the conveyor belt 12 to be varied to suit production requirements.

The pressure roller or embossing assembly 14 includes a pair of substantially level spaced apart pressure rollers 34 and 36 which are supported by horizontal arms 38 and 40 that extend from a structural supporting member such as one of the conveyor support members here designated 41. These arms 38 and 40 may be secured to member 41 by any suitable means such as bolts 42. A single roller supporting shaft 44 extends through member 40 and rotatably carries roller 36. It is also used to accommodate other adjacently positioned rollers which cooperate to provide an indefinite number of embossing assemblies and which are described in full detail subsequently. Another shaft 46 extends through arm 38 and singularly supports roller 34.

FIG. 3 particularly illustrates the pressure roller assemblies 14-01: the embossing apparatus 10. Since a number of roller assemblies is desirable in that they are constructed so as to expose embossing and etching means to a plywood surface in a manner to avoid repetition in design, shaft 44 serves as a drive shaft and a common axis for roller 36 and adjacently positioned rollers 48, 50, and so on depending on the number of assemblies 14 desired. Additional horizontal arms 52 and 54 follow member 34 and are of varying lengths so as to position subsequently placed rollers 56 and 58 at varying distances from their cooperating rollers 48 and 50. Since all roller pairs are at different spaced apart distances each from the other, no two embossing and etching surfaces will ever coincide so as to form a continuous or repetitive pattern onto the finished surface 51 of a plywood panel 13 or other wood. This will avoid undesirable repetitive patterns that would mar a wall or furniture surface by indicating that the simulated wormy effect is indeed simulated. Members 38, 52 and 54 are additionally supported by angled members 60, 62 and 64 and are held in place by conventional means such as bolts 66. Note that each of rollers 34, 56 and 58 have separate shafts 46, 68 and 70 respectively. An additional structural configuration depends about arm carrying member 71 which attaches to strut 18 and assists in maintaining shaft 44.

Shaft 44 carries at one end, a notched drive pulley 72 which is rigidly secured by conventional means '74 so as to cause shaft 44 to rotate positively as the pulley 72 is turned. A conventional electric motor 76 with a suitable gear reduction box 78 is employed and utilizes a pulley 80 to drive a drive belt 82 so that shaft 4 1i may be rotated as belt 82 turns pulley 72. The incorporation of gear reduction box 7% allows assemblies 14 to be driven at the same speed as the conveyor belt 12; thus motors '76 and 24 can be commonly wired and gear boxes 78 and 52 gang-operated so as to insure the same operational speed for each of the mechanisms.

A continuous track or web 84 spans the periphery 85 of each pair of pressure rollers such as rollers 34 and 36 as shown in FIG. 1, and it has been found desirable to provide the interior surface of web or track 84 with engaging notches 86 which will be cooperatively received within recesses 88 along the periphery 85 of pressure rollers such as 34 and 36 as shown in FIG. 1. The mating of notches 86 within recess 88 provides a positive drive for the web 84 andinsures that the embossing and etching means will make contact with the surface of an advancing plywood panel 13 or the like for a precise time interval which operation will be described subsequently in detail.

Track 84 releasably supports by screws 90 or other conventional means a plurality of adjacently positioned segments 92 formed of any heat resistant material, and these segments 92 in turn threadably retain 94 a plurality of randomly arranged embossing or woodburning tools generally designated 96. These embossing or woodburning tools 96 comprise a base portion 98, a track engaging portion 100 which is disposed rearwardly of the base portion and is threaded to be accommodated within the threaded recess 94 of segment 92, and a tip or searing needle 102 extending forwardly and substantially outwardly from base portion 98. Note that needle 102 may take any number of forms or shapes such as shown in FIG. 6, the examples there particularly illustrating a straight perpendicular hole forming needle 104, a slightly bent inclined hole forming needle 106, an angularly bent groove forming needle 108, and an arcuately bent recess forming needle 110.

The finished surface pattern 51 illustrated in FIG. 7 is remarkably similar to the actual wormy effect found in natural wormy chestnut though it has been produced by needle tips or points such as those shown in FIG. 6.

The releasable characteristic of the individual segments 92 to track or web 84 allows expeditious replacement of such segments should they become damaged or destroyed during operation of the apparatus 10 with belt 12. Additionally, the embossing or woodburning tools 96 are easily replaced when they are damaged by simply unscrewing them from their engagement 94 with segment 92 and substituting new threaded units. A conventionally shaped nut 112 integrally formed with body portion 98 allows these tools 96 to be removed by an ordinary wrench or pair of pliers.

A number of panel guides 114, 116, 118 and 120 are positioned at preselected intervals along the conveyor belt 12 to guide advancing plywood panels such as designated 13 in registry toward and in contact with the embossing and etching means as particularly illustrated in FIG. 2. As a plywood panel 13 advances and contacts the plurality of pressure roller assemblies 14, the differing spaced-apart relationships between the various rollers 34 and 36, 48 and 56, '50 and 58, and so on, cause a simulated wormy chestnut oak pattern 51 to be applied to the finished surface of each plywood panel 13 as it is advanced while in contact with the embossing and etching surface formed by the segment carrying tools 96 of each of the assemblies 14, 14a, 14b, and the like. The panel 13 then emerges from the embossing apparatus 10 with a random pattern 51 on its finished surface ready for subsequent shipment and use.

In order that the embossing tools 96 be heated to a predetermined temperature sufficient to sear, perforate and etch the surface of the advancing panel 13 to simulate a wormy effect, it is necessary that heat be applied primarily to these tool tips 102, 104, 106, etc.; however, it is vital that the heat be applied for a precise period of time in order to avoid overheating the tips and damaging them or heating them to an extent that will not only burn a simulated Wormhole but also score the surrounding plywood panel surface and thus mar the finish of the resulting product. A number of equally satisfactory heating means are contemplated in the present invention, and FIG. 1

illustrates the application of infra-red rays through a lamp bank 122 having a number of individual infra-red lamps 123 to embossing tool tips 102 just prior to their contact 124 with the finished surface of advancing plywood panels. Once the tools make contact 124 with the surface, they are held there-against until pulley 34 or its adjacent pulleys 56, 58, etc., lifts web 84 or its equivalent and its carried segments 92 and tools 96 at a location 126. Since the distance between cooperating pulleys differs, the disengaging locations will also differ. The positioning and time interval for exposing the tools 96 and their respective needles 102 to the infra-red rays depends, of course, on the material used for the embossing tool tips and the duration of contact that each tip has with the plywood surface as panel 13 moves through the embossing apparatus 10.

An equally satisfactory method of heating the embossing tools 96 to a temperature sufficient to sear, perforate and etch the plywood surface to simulate a wormy effect is the provision of a plurality of electric circuits which incorporate as a series circuit component or parameter, at least the tips 102 of tools 96 so that upon energization, these members, being of a high resistance metal, become heated to a temperature sufficient to sear and decorate the surface of a panel 13 with a simulated worm distressed pattern. Any number of equally good switching arrangements can be used so that for one portion of the track movement, the circuits are made and a common potential is supplied thereto, thus heating the tool needles 102, as a series resistance, to a desired temperature. At a second preselected position, the circuit is broken and the heat accumulated in the embossing tool needles is transferred to the surface of the plywood panel 13 or related material to score that surface and achieve a simulated wormy effect. Obviously, many different heating circuits and switching arrangements can be used, and such are well within the skill of those in the embossing art. Heating means such as disclosed in US. Patent No. 2,419,271 to Henry Lish and US. Patent No. 2,703,463 to C. T. Mc- Elroy disclose still other variations of heating mechanisms that might be appropriate for this particular apparatus and application.

Several alternative embodiments of the embossing apparatus are proposed and illustrated, and the apparatus shown in FIG. 8 as representative of one such alternative embodiment incorporates a plurality of pressure rollers or drums 128 each bearing a plurality of embossing tools 130 and each being of a different diameter so as to avoid a repetition or duplication of patterns on a plywood panel or like material 132 that is passed therethrough. A drive 134 utilizing a common pulley or belt 136 rotates all pressure rollers 128 in the desired direction by the use of intermediate idlers 138. A continuous conveyor belt 140 moves the panel 132 into engagement with embossing tools 130 along roller peripheries 142.

An additionally proposed embodiment 144 incorporates a pressure roller assembly 146 in juxtaposition with an essentially similar assembly 148, both assemblies moving uni-directionally to accommodate plywood panels 150 passing therebetween. When using embodiments such as illustrated in FIG. 8 and 9, it has been found desirable to incorporate a biased embossing member generally designated 152 which is reciprocally maintained in the surface of the drum or cylinder 142 and is continuously urged outwardly by a seated helical spring 154 carried on an extending shaft 156. A pivotable foot or embossing head 158 is movably positioned so as to engage a flat surface no matter what its angle of approach in a positive and complete manner. The embossing surface 160 of head 158 can be designed to give the same simulated wormy appearance as achieved through the use of embossing tools 96 in the preferred embodiment of the present concept. The use of the resilient pivotable member shown in FIG. 11 is particularly helpful when an embodiment such as shown in FIG. 8 is contemplated because the embossing tools 130 are carried on the periphery 142 of the individual drums 128. Thus when a drum rotates so as to'cause the embossing tool 130, which is similar to the unit shown in FIG. 11 and generally designated 152, to engage the surface of a plywood panel 132, the tool will contact the panel along the embossing surface 160and will remain adhered thereto under uniform pressure for a longer duration since shaft 156 will become recessed within the interior 162 of the drum 128 by sliding within the cylinder wall 142. As the drum continues its rotation the spring 154 will maintain the embossing tool against the plywood surface for a maximum period of time under a consistent pressure suificient to score that surface. This allows a maximum time period for contact between the embossing members 152 and the panel so as to assure adequate burning and patterning.

A final proposed embodiment is shown in FIG. and incorporates the use of a slated conveyor assembly generally designated 162 for accommodating advancing plywood panels 164. Additionally, a plurality of metal particles 166 small in size and irregular in shape are continuously circulated and distributed over the advancing panels through a distributing assembly 168 comprising a spreader 170 and receptacles 172. Conventional heating means 174 elevates the temperature of metal particles 166 prior to their passage into receptacles 172 and distribution over spreader 179. Once the metal particles 166 fall to the surface of the plywood or like material panel 164, their contained heat is transferred to the relatively cool surface of the panel to sear and etch a simulated wormy effect thereon. The particles are then passed down the incline 176 of the panel surface to a collector 178. Once collected, they are gathered by a conveyor chute 180 having a plurality of pockets 182 to raise these particles upwardly and into the heating means 176 for subsequent distribution and recirculation.

It is to be understood that any number of equally satisfactory embossing devices may be used in lieu of either an electrically heated or gas fired drum. This, of course, would include any number of gas jet configurations along with any other heating devices that would allow the embossing tools to become heated to a high temperature for subsequent etching of plywood panels and the like. These heating means are equally applicable to any of the alternative embodiments contained in this application along with the preferred embodiment.

It may thus be seen that there has been provided a novel and useful means for embossing wooden panels particularly those made of plywood to form patterns of simulated worm deterioration. By virtue of the means disclosed, relatively large production may take place with a low manpower requirement, thus allowing reduced costs of production, and greater distribution, sale and use.

While the foregoing discloses what is now contemplated to be the best mode of carrying out the invention and several additional modes are illustrated, the same is, of course, subject to modification without departing from the spirit and scope of the invention. Therefore, it is not desired to restrict the invention to the particular combinations described, but to cover all equivalent means that may fall within the scope of the appended claims.

Having thus described this invention, what is claimed is:

1. An apparatus for distressing wood panels by searing and etching the dressed panel surfaces comprising: means for moving said panels along a directed path of travel; means engageable with the finished surfaces of advancing wood panels to sear and etch said panels and to form a random pattern simultating the natural distressed appearance of wormy wood; means operable with said searing and etching means to elevate selectively the temperature thereof; and guide means for directing said panels in registry against said searing and etching means for selected time intervals.

2. An apparatus for distressing wood panels according to claim 1, said searing and etching means including at 8 least one pressure roller revolvably positioned adjacen said panel advancing path, means to rotate said roller, a plurality of woodburning tools releasably secured to the periphery of said roller, said means being engageable with the finished surface of advancing wood panels to form a random pattern simulating a natural distressed appearance of wormy chestnut; and means to selectively elevate the temperature of said tools.

3. An apparatus for distressing wood panels according to claim 1, said searing and etching means including at least one pressure-burning assembly having a pair of pressure rollers revolvably positioned adjacent said advancing means, means for rotating at lea-st one of said rollers, a continuous conveyor track having a plurality of movably attached track segments and spanning said rollers for movement in response to roller rotation, a plurality of woodburning tools replaceably positioned on each of said track segments in a random fashion, said tools extending outwardly and substantially perpendicular to the direction of movement of said segments to contact, scar and perforate a wood panel moving along said panel advancing means adjacent conveyor track, and means proximate said track for elevating the temperature of said tools during selected intervals to a level sufficient to cause said tools to scar and etch an advancing wood panel positioned in contact therewith and to form a random pattern simulating the natural distressed appearance of wormy chestnut.

4. An apparatus for distressing wood panels according to claim 1, said searing and etching means including a plurality of woodburning metal particles, means for randomly distributing said particles onto said advancing panels, a particle collecting receptacle, means for removing said particles from advancing wood panels and means for moving said particles from said receptacle to said distributing means.

5. An apparatus for distressing wood panel-s according to claim 1, said temperature elevating means including electrical circuits adapted to selectively contain said searing and etching means as series circuit parameters, a source potential and switching means to selectively apply said potential to said circuits, said parameters having a high resistance and becoming heated upon the application of said potential to said circuits so as to sear and etch an advancing wood panel positioned in contact therewith to form a random pattern simulating the natural distressed appearance of wormy wood.

6. An apparatus for distressing Wood panels according to claim 1, said temperature elevating means including electrical circuits adapted to selectively include said searing and etching means as parameters thereof, a source potential and switching means to selectively apply said potential to said circuits.

7. An apparatus for distressing wood panels according to claim 1, said temperature elevating means including a plurality of infra-red lamps positioned proximate said searing and etching means, said lamps being selectively activated to heat said searing and etching means at a position prior to the contact of said means with advancing panels.

8. An apparatus for disetressing wood panels according to claim 2, each of said woodburning tools including a base portion, a track engaging portion disposed rearwardly from said base portion, and a searing needle extending forwardly and substantially outwardly from said base portion, said needle shaped to fashion a simulated Wormhole as it burns into a wood panel.

9. An apparatus for distressing wood panels according to claim 2, each of said woodburning tools including a roller engaging shaft having a flange, one shaft end and socket receiving recess formed at the other shaft end, a movably retained embosser positioned within said recess and a helical spring slidably held about said shaft to yieldably urge said shaft to a fully extended outward position perpendicular to said roller periphery, said embosser 9 shaped to fashion a simulated Wormhole as it burns into a wood panel.

10. An apparatus for distressing Wood according to claim 3, each of said woodburning tools including a base portion, a track engaging portion disposed rearwardly of 5 said base portion, and a searing needle extending forwardly and substantially outwardly from said base portion, said needle shaped to fashion a simulated Wormhole as it burns into a Wood panel surface.

1 0 References Cited UNITED STATES PATENTS 1,941,394 12/1933 Forsyth 144328 2,419,271 4/1947 Lish 1019 2,703,463 3/1955 McElroy 144328 BERNARD A. GILHEANY, Primary Examiner.

R. N. ENVALL, Assistant Examiner. 

